Jon Miller, Author at Gemba Academy

Toyota to Reduce Span of Control in Engineering

By Jon Miller - June 14th, 2010

The Nikkei reported on June 11, 2010 that Toyota is bringing back front line supervisors, adding a layer of management to staff positions that has been missing since 1989. This is an admission by Toyota, the world’s greatest lean

21 Questions to Ask When Walking the Model Line, Part 2

By Jon Miller - June 9th, 2010

Continuing our walk on the model line, here are questions 11 through 21 to ask when performing a lean maturity audit: 11. What methods are used to smooth out the variation in workload due to changes in product mix or work volume? What

21 Questions to Ask When Walking the Model Line, Part 1

By Jon Miller - June 8th, 2010

The model line is a value stream or a section of a value stream used as a pilot to demonstrate an organization’s capability to deploy lean systems and behaviors. The model line approach is used early in an organizations lean jour

Leaders Who Think Across Silos

By Jon Miller - June 5th, 2010

A Newsweek article titled ‘Know What You Don’t Know’ interviews Cisco Systems CEO John Chambers and plumbs his insights into the futre of leadership. One passage caught my eye in paticular: You came out of law school

Good Fortune Deceives, but Bad Fortune Enlightens

By Jon Miller - June 3rd, 2010

Previously we made an analogy between King Pyrrhus and Toyota’s cost of victory in the battle for sales volume. I recommend the Classics once again as a source of wisdom for leaders. In the most challenging of times they could be

Enhancing Total Management Commitment

By Jon Miller - June 2nd, 2010

In an e-mail, Junaid asked: How we will enhance top management commitment and involvement for implementation of Total Productive Maintenance (TPM)? This is a great general question to ask for any effort to establish excellence, maintai

Fake Lean and the Spotting Thereof

By Jon Miller - May 31st, 2010

If the peddlers of fake lean were as easy to spot as antler salesmen we would have a much easier time staying free of them. I’ve seen some great deals on antlers, and like the emperor’s clothes, the many leaders who have pa

The Fine Print About Lean Transformations

By Jon Miller - May 27th, 2010

Here’s the deal. If you call between now and July 1, 2012 we will guarantee a full 5X return on investment for a lean transformation! Benefit now and pay in 24 easy monthly installments. No capital investment is required. Ready t

The Original Kamishibai

By Jon Miller - May 25th, 2010

By pure chance I came across a book on display at the local public library titled Manga Kamishibai: The Art of the Japanese Paper Theater by Eric P Nash. It is a history of the paper theater art form from the 1930s to modern times. The

Review of Building a Lean Fulfillment Stream

By Jon Miller - May 24th, 2010

Building a Lean Fulfillment Stream: Rethinking Your Supply Chain and Logistics to Create Maximum Value at Minimum Cost by Robert Martichenko and Kevin von Grabe is the latest publication from the Lean Enterprise Institute. The book gui

How to Set Span of Control for Leaders

By Jon Miller - May 21st, 2010

Earlier in the week Jamie Flinchbaugh started a great conversatoin when he asked “what is the right span of control for a manager?” Jamie defined span as: “…how broad an individual managers responsibility is def

Where Old Dogmas Go to Die

By Jon Miller - May 16th, 2010

The death of dogma is the birth of morality. That’s a bit of winning 18th century philosophy from Immanuel “Never Say” Kant. Morality is the knowing of right from wrong at the level of truth. Dogma is personal opinion

Never Start with 5S!

By Jon Miller - May 4th, 2010

“Oh no,” some of you are thinking. “Too late! Why didn’t you tell us earlier?” Jamie Flinchbaugh started a thought-provoking discussion today on his blog where he says don’t do 5S and gives good reas

The Will, the Willow and the Frog

By Jon Miller - May 2nd, 2010

Change is like the boughs of the willow in a breeze. We can seldom control more than the very leaves and tips of branches, never the whole tree itself. When faced with absolutely solvable problems going unaddressed or imaginable future

An Infinite Number of Solutions…

By Jon Miller - April 30th, 2010

…may seem like a good thing. After all, the more solutions we have to any particular problem, the more likely we are to solve it right? In actual practice when we are properly constrained we are more likely to spend our time and

Three Questions about Standardized Work in the Office

By Jon Miller - April 27th, 2010

A client asked an earnest question. I have my opinions but not observed facts. In fact I have heard conflicting information on this issue, with respect to Toyota. How does Toyota manage their support staff documentation? Around what %

What to Do When Your Lean Implementation is Like a Chicken

By Jon Miller - April 25th, 2010

Premanath asked: What is skill matrix and before starting skill matrix what should be known? Nice two-part question. The first part is relatively easy and has little to do with chickens. The skill matrix is a document that displays the

The Necessity of Redundancy

By Jon Miller - April 21st, 2010

After every major natural disaster that disrupts global supply chains there are voices that cry out “A-ha! I told you just in time doesn’t work!” So with the Icelandic volcano turning European skies airoplane-free for

A Tracking Method for 5S Programs

By Jon Miller - April 20th, 2010

David asked: I’m having a difficult time coming up with a tracking method for our 5S program. We are running a program with a scoring value but no real tracking method. Any suggestions? We have to pause every time we hear the wor

Ten Tips for Better Facilitation

By Jon Miller - April 18th, 2010

Facilitation is the art of guiding but not leading, bringing learning but not lecturing, engaging but not directing. Coming from the Latin facilitar meaning “to make easy” the role of the facilitator is not to do for others

My Suggestion to Improve Long Beach Airport

By Jon Miller - April 11th, 2010

Long Beach Airport is tiny, has oddly artistic lines and is blessed with palm trees set against a blue sky. The airport’s single terminal ends almost before it begins. Baggage claim is a short stretch of conveyor, outside of the

Ambiguous Visual Controls: Waste Please

By Jon Miller - April 7th, 2010

There is something sinister about a place that calls itself “the happiest place on earth”. How did they arrive at that superlative conclusion? Did they benchmark GNH (Gross National Happiness) against other locations on ear

The Checklist Manifesto: How to Get Things Right by Atul Gawande

By Jon Miller - April 6th, 2010

I just finished reading and thoroughly enjoyed The Checklist Manifesto: How to Get Things Right by Dr. Atul Gawande. I recommend it. Mark Graban at the Lean Blog has written passionately and at length about the value of checklists in i

Five Most Terrifying Words for a Lean Thinker

By Jon Miller - April 2nd, 2010

The check was not performed. These words were spoken today during a meeting to review an ongoing and complex problem solving effort within Gemba. These words chilled me to the bone. The failure to perform a check is far more dangerous

The Business Complexity Accelerator at Toyota

By Jon Miller - April 1st, 2010

There was an interesting article in the Knowledge@Wharton newsletter today. Wharton management professor John Paul MacDuffie interviewed Toyota expert, author and Tokyo University Professor Takahiro Fujimoto. The piece is called Under

Jon Miller

Find Jon Elsewhere

Start your improvement training today.